Refractory Maintenance Master Engineer

Vale; Schamal al-Batina; On-site; OMR 23,000 - 38,000; Full time

Job summary

Vale in Oman is seeking a Master Refractory Engineer to lead development of refractory maintenance strategies across two pelletizing plants employing Travelling Grate, Rotary Kiln and Annular Cooler technologies. You will define asset management plans, maximize campaign life, improve availability and reliability, and oversee maintenance contracts.

The role requires extensive experience in refractory engineering, RCFA, FMEA, thermography, and collaboration with suppliers.

Job description

• Responsible for the development of the process routes for mineral projects and the implementation of new methodology and procedures in the refractory maintenance of the equipment, emphasizing technological improvement and the monitoring of innovative technological solutions, aiming to increase the availability and productivity of the equipment.
• The Master Refractory Engineer is the technical authority responsible for the refractory systems across two pelletizing plants utilizing Travelling Grate, Rotary Kiln and Annular Cooler technologies.
• The role is accountable for defining and implementing the refractory asset management strategy, maximizing refractory campaign life, improving equipment availability and reliability, developing innovative refractory solutions, establishing predictive condition monitoring programs, managing refractory maintenance contracts, and ensuring world-class refractory maintenance practices.

Job Summary

• Responsible for the development of the process routes for mineral projects and the implementation of new methodology and procedures in the refractory maintenance of the equipment, emphasizing technological improvement and the monitoring of innovative technological solutions, aiming to increase the availability and productivity of the equipment.
• The Master Refractory Engineer is the technical authority responsible for the refractory systems across two pelletizing plants utilizing Travelling Grate, Rotary Kiln and Annular Cooler technologies.
• The role is accountable for defining and implementing the refractory asset management strategy, maximizing refractory campaign life, improving equipment availability and reliability, developing innovative refractory solutions, establishing predictive condition monitoring programs, managing refractory maintenance contracts, and ensuring world-class refractory maintenance practices.

MAIN CHALLENGES

• Increase the availability and the productivity of the equipment’s by introducing a new methodology in doing the maintenance safely, proactively and with quality and minimizing the down time.
• Monitor the equipment’s performance by following up all the reports which is displaying the performance and predicting any issues / challenges may happen in the future.

Main Responsibilities

• Refractory materials selection, Castables and gunning applications, Brick lining systems.
• Refractory failure analysis, Thermal degradation mechanisms, Dry-out and curing procedures.
• Refractory installation quality assurance, Lifecycle extension strategies.
• Root Cause Failure Analysis (RCFA), FMEA methodologies, Reliability engineering principles.
• Thermographic inspections, Endoscopy, Shell temperature monitoring, Refractory wear monitoring techniques.
• MTBF and availability analysis.
• Contract Management, Development of SOW packages, Technical bid evaluations.
• Contract administration, Budget control, Vendor performance evaluation.
• Team leadership and mentoring.
• Strong communication and stakeholder management.
• Problem solving and decision-making.
• To create Inspection and Preventive Maintenance Plan for the Refractory Activities;
• To conduct Failure Analysis specifically for refractory;
• To define refractory activities during the Shutdowns;
• To improve the lifecycle for refractories;
• To ensure the correct discharge of refractory waste;
• To define the standards for refractory execution activities considering Health and Safety guides;
• Participate in the refractory budget preparation of the area and maintain the cost efficiency.
• Elaborate and evaluate indexes for management, looking at a higher reliability and lower cost.
• Mentor and analysis the area KPI and suggest the best solutions.
• Maintain the corporate assets in good state of conservation, aiming at a low-cost operation and prioritizing environment, health and safety.
• Prepare Contract SOW to perform a maintenance service and evaluate the technical proposals.
• Prepare and review JSA & SOP for the activities related to the department.
• Controlling / Managing the contracts as per the guidelines & procedures of contract department.
• Evaluate & approve the technical proposal and purchase requests.
• Manage the availability of the required spare parts of the equipment’s in the plant.
• Providing a technical advice and support to the lower level of employees and insuring a high-quality standards in maintenance activities.
• Prepare maintenance activity procedures and follow up the implementation as per health and safety policies and procedures.
• Participate in the planning of the maintenance activities and the annual stoppages
• Develop new materials and technologies for maintenance activities and equipment’s.
• Ensuring operation and maintenance activity is done as per the manufacture recommendation.
• Monitor the execution team activity to maintain a high level of quality job.
• Identify resources to develop the technical skills of the team as well as the maintenance services
• Realize technical and economic feasibility studies for equipment’s and projects.
• Update the maintenance through innovations available in the market.
• Support maintenance team in preparing the strategy of equipment’s maintenance and reviewing the maintenance plan based on availability, inspection & historical data.
• Discuss and solve complex problems with manufacturing companies, sub-contractors & suppliers.
• Diagnose breakdown problems and prepare a technical Report for major breakdown.
• Advanced Refractory Expertise: API 936 Refractory Certification.
• Experience with refractory design software, Thermal modeling expertise.
• Kiln heat transfer analysis, Process optimization projects in pelletizing plants.
• Material Development & Research, Experience developing new refractory materials.
• Laboratory characterization techniques, Refractory testing and qualification programs.
• Collaboration with refractory manufacturers for product development.
• Publication or presentation of technical papers.

(*) At any time, Vale can review, at its own discretion, the job roles and responsibilities according to its strategy.QUALIFICATION

• Graduation: Bachelor's Degree in: Materials Engineering, Ceramic Engineering, Metallurgical Engineering or Chemical Engineering.
• Master's Degree is desirable.
• Specific knowledge: English Speaking and Writing.
• Minimum 15 years of experience in refractory engineering.
• Minimum 05 years of experience in pelletizing, ironmaking, steelmaking, cement, lime or other high-temperature industrial processes.
• Demonstrated experience with: Travelling Grate systems, Rotary Kilns, Annular Coolers and Gas Generators.
• Refractory maintenance planning.
• Refractory inspections.
• Material and Refractory Process Development.
• Shutdown management.